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United States Patent Q
3,030,706
CC
Patented Apr. 24, 1962
1
2
type of electrode frequently used is low-metaloid ferrous
3,030,706
stock. A common speci?cation for this is
ALUMINUM COATED WELDING ELECTRODE
Percent max.
AND METHOD OF PRODUCING THE SAME
Ronald E. Griffiths, Cleveland Heights, and Arch W
Carbon _
Harris, Warrensville Township, Cuyahoga County,
Manganese
Ohio, assignors to United States Steel Corporation, a
_
____
___.
.05
_
.17
Phosphorus _______________________________ __ .025
corporation of New Jersey
No Drawing. Filed Jan. 11, 1955, Ser. No. 481,258
2 Claims. (Cl. 29-528)
_
Sulphur
'
__
___
____
.035
Silicon ___________________________________ __
.03
Copper ____ __
.05
____
_
We have successfully formed coated electrode of’such
This invention relates to improvements in the manu
stock containing:
facture of welding electrodes.
One of the problems encountered in fusion welding
Percent
Carbon ___________________________________ __ .05
wherein the electrode provides the source of deposited
metal is porosity in the deposited metal which lowers the 15 Manganese ________________________________ __ .12
Phosphorus _______________________________ __ .012
strength thereof. Since aluminum is a known deoxidizer,
Sulphur
._
_
._
___
.035
it has been proposed to add aluminum to the welding
Silicon ___________________________________ __
.01
electrode but this renders ferrous metals incapable of
Balance iron and residual impurities.
being formed and drawn into Wire of the desired size.
We have discovered however, that predominantly alumi 20 Wire of 14;" diameter of this steel was heated in air
num coatings, if applied in accordance with the teachings
to remove the lubricants thereafter and was thereafter
of our invention can be used to advantage in many types
pickled in a 10% ‘by weight hydrochloric acid solution
of welding.
In present day continuous welding machines, the elec
to remove any oxide on the wire. As it left the pickling
bath, the wire was washed in hot water and introduced
trode wire is continuously fed through a welding head 25 into a nonoxidizing atmosphere comprising dissociated
wherein it makes a sliding electrical contact with a sleeve
ammonia and heated therein to a temperature of about
through which the welding current is applied to the wire.
1250“ F. Without exposure to air, it was then introduced
Thus the surface of the electrode must be smooth and
into a bath of a substantially pure aluminum except for
abrasion resistant. Moreover, to be fully effective as an
contaminating elements, maintained at a temperature of
electrode, the aluminum coated wire must not only have 30 about 1250° F. The time of immersion was regulated
a smooth surface but also the aluminumgcoating must
to produce a coating having a weight of .3 ounce per
be of uniform thickness.
square foot of wire surface. After solidi?cation, the
‘It is accordingly an object of our invention to provide
coated wire was cold drawn to reduce the diameter
an improved welding electrode and method of producing
the same.
35
In accordance with the teachings of our invention, wire
to be coated is cleaned by conventional practice, such
as heating in air or a lead pan to burn off any lubricants
“thereon and pickled in an acid solution to remove any
about 11%.
Electrodes coated with aluminum as above, permit, in
the case of ferrous base metal, higher amperage welding
currents since aluminum is a better conductor than iron
and thereby permits higher welding speeds. The alumi
num produces more ?uidity in the weld deposit and this
oxide. It is thereafter quickly introduced into a reducing 40 along with its deoxidizing effect produces more uniform
or nonoxidizing atmosphere wherein it is heated and then
deposits with greater freedom from porosity, particularly
introduced in a bath of molten aluminum while still pro
in the so-called “automatic” types wherein the arc is
tected by such atmosphere. The wire is heated to at
shielded by gas or the metal is deposited under a blanket
least 1200° F. and preferably to the bath temperature.
of flux.
The bath may be relatively pure aluminum except for 45
While we have shown and described several speci?c
impurities or may contain up to about 12.5% silicon to
embodiments of our invention, it will be understood that
reduce the formation of the brittle intermetallic iron
these embodiments are merely for the purpose of illus
aluminum alloy. The molten coating bath is maintained
tration and description and that various other forms may
at a temperature between 1225“ F. and 1300° F., prefer
be devised within the scope of our invention as de?ned in
ably about 1250“ F., and the time of immersion is regu 50 the appended claims.
lated to produce a coating weighing less than .40 ounce
We claim:
per square foot. The coated wire is withdrawn from the
1. A method of producing‘ aluminum coated electrodes
pot and the coating solidi?ed thereon.
of low-metalloid ferrous stock comprising forming elec
Following solidi?cation, the coated wire is cold drawn
trode stock of steel containing
through a reducing die at least enough to work the coat~ 55
Percent maximum
ing throughout.
To achieve this the diameter of the
coated wire must be reduced at least about 10% in cross
sectional area.
The wire forming the base metal may be any metal that
it is desired to deposit. In most forms, it will be ferrous 60
metal of plain carbon, alloy or “stainless” grades. Non
ferrous metals such as titanium, nickel, copper and alloys
thereof may be coated. As in all fusion Welding, the
base metal used is designed to give a weld bead of simi
Carbon ___________________________________ __ .05
Manganese ________________________________ __ .17
Phosphorus _______________________________ __ .025
Sulphur ___________________________________ _. .035
Silicon ___________________________________ __ .03
Copper ___________________________________ __ .05
with the balance substantially iron, cleaning said stock,
heating said stock in a nonoxidizing atmosphere to at
lar characteristics as the metal being joined together. One 65 least 1200. F., passing said stock through a coating bath
comprising molten aluminum, maintaining the tempera
3,030,706
3
ing the coating thereon and then cold drawing the coated
electrode stock to produce a compact, uniform aluminum
coating on said stock.
2. A method of producing aluminum coated electrode
area at least about 10% to produce a compact uniform 7
aluminum coating thereon.
of low-metalloid ferrous stock comprising forming elec
References Cited in the ?le of this patent
UNITED STATES PATENTS
trode stock of steel containing
Percent maximum
Carbon ___________________________________ _ _
.05
Manganese ________________________________ __
.17
4
tain the applied coating to less than .4 ounce per square
foot, solidifying the coating thereon and then cold draw
ing the coated electrode stock to reduce the cross-sectional
ture of the bath between 1220° F. and 1300” F., soldify
10
1,277,639
Pescatore ____‘ _________ __ Sept. 3, 1918
1,794,983
Ritter ________________ __ Mar. 3, 1931 ,
Phosphorus ____ __' __________________________ __. .025
2,319,977
Cape et al _____________ -_ May 25, 1943
Sulphur __________________________________ _._ .035
2,543,936
2,686,355
Reynolds _____________ __ Mar. 6, 1951
Lundin ______________ __ Aug. 17, 1954
Silicon
___________________________________ _ _
.03
Copper ____________________________________ _ _
.05
OTHER REFERENCES
15
cleaning said stock, heating said stock in. a nonoxidizing
“The
Metal-Iron,”
by Cleaves and Thompson, ?rst edi
atmosphere to about 1250° F., passing said stock through
tion, published for The Engineering Foundation by Mc
a coating bath comprising molten aluminum, maintaining
GraW-Hill Book Company, 'Inc., 1935, (page 72 relied
said bath at a temperature of about 1250° F., regulating
20
on).
(Copy in Division 3.)
the time of immersion of said stock in said bath to main